ISO 22K OPRPs - OPRPs in food processing industry

Dear all,

our company has recently introduced in food processing (Mango & Guava pulp & Pome. juice Conc.). Previously we were in fresh produce exports and have experience of BRC certification. Presently we are going for ISO 22000.
I have prepared HACCP plan and some imp. procedures but i am feeling difficulty in preparing OPRPs.
I will be grateful if any one can give the example (Model) of documented OPRPs manual (Log).

Thanks and Regards,

Sachin Saindane

BUMP for Sachin.

Dear Sachin,

Nice thing that you people are moving towards ISO22000. In my opinion, you shall stick to the SEQUENCE mentioned in standard. How can you develop a HACCP plan without following the correct sequence of standard?

Correct sequence is :

Step 1- Define your food safety team
Step 2- Appoint a food safety team leader
Step 3- Document organization's food safety policy statement
Step 4- Document organization's food safety objectives
Step 5- Develop Specifications of Raw material, ingredients and Product Contact Material
Step 6- Develop specification of YOUR finished product including the intended use (Clause 7.3.4)
Step 7- Prepare process flow chart and process description (including the control measures)
Step 8- Conduct Hazard Analysis, Control Measure categorization and extract OPRPs and CCPs
Step 9- Develop your OPRP and HACCP Plan (including all requirements of 7.5 and 7.6)

After hazard analysis, when you jump to categorization of control measures, then you categorize the CONTROL MEASURES into OPRP and CCP.

If you share the flow diagram and process description, then surely one of us would help you in developing the correct OPRP and HACCP plan.



Regards
Siraj

Thank u very much Siraj,

I have found your prompt replies on many topics and feeling lucky to have the experienced friends like you in this forum.
The checklist given by you is the same i had prepared few days before my self and i had finished most of the tasks upto No. 7 as given by you. Also i had prepared some procedures against clause No. 4.2, 5.4,5.7,5.8,6.2.2,7.8, 7.10, 8.3, 8.4.1 & 8.5.

I am confused about Cause No. 8.2, 8.4.2 & 8.4.3 and seeks guidance about recording system of these.
In the attachement you can found 3 sheets of process flow in a single excel sheet and 3 another files of process description for each product.(Sorry for inconvenience as it will take significant time to go through this all)

Please guide me what are the correct OPRPs & HACCP plan. If u can give examples to be documented the same then it will be appreciable.

Thanks again for your efforts.

Regards,
Sachin Saindane

is it important to make hazaras analysis and flow chart for every product , where it is cataogrized under the same type fruites


please any one help

is it important to make hazaras analysis and flow chart for every product , where it is cataogrized under the same type fruites


please any one help

Hello everybody,

can any one of senior members will guide to prepare OPRPs & HACCP plan by taking reference of process flow chart and process description that i have attached in my previous post.

Thanks & Regards,

Sachin Saindane

Dear Sachin,

Thank you for the attachments you hv provided.

I am not a user of 22000 but I have followed the various contributions made with some interest. I can make a few comments on yr data which will hopefully encourage other users to further elaborate.

I assume you hv read iso 22000 and ISO 22004.

I assume you hv read the attachments / examples which were previously posted by Bennii / Modarres /Shakti and the suggestion(s) of S.U.Siddiqui

Comment1 – the (traditional) selection point of CCPs as in yr attachments has been modified in 22000 by application of the decision step based on 7.4.4

Comment 2 – in view of all the “shalls” in the standard, I presume the detailed categorisation step 7.4.4 is mandatory. This seemingly necessitates analysis as per the attachments referred above. Unfortunately, some of the relevant info. is probably specific to you and not known to other readers which makes predicting things a bit difficult. Nonetheless, Bennii’s example seems to point one way. (Actually a decision tree existed in a pre-final draft to the standard [which I posted earlier] but this was seemingly regarded as too “simple” and dropped.).
One possibility would be for you to try 2-3 process steps of one product (eg containing a likely CCP / oprp), carry out the analysis and repost this table for comments perhaps.

Comment3 – It is conceivable that some auditors are accepting yr present style of HACCP presentation followed by a more simpler continuation to select the oprps (eg the control measures remaining after separating the prps / ccps and which can then satisfy 7.5 ??). Regret I hv no information on that.

Rgds / Charles.C

Please go through FCI HACCP manual for same.

. Also i had prepared some procedures against clause No. 4.2, 5.4,5.7,5.8,6.2.2,7.8, 7.10, 8.3, 8.4.1 & 8.5.



Regards,
Sachin Saindane

Sachin,
Dont forget the mandatory document related to 7.4.4.

Dear Sachin
I have gone thru the attachments. It is quite well prepared flow diagram, only to keep the requirement in mind you should review the same.
As per clause 7.3.5.1
Flow diagram shall be clear, accurate and sufficiently detailed, as appropriate, include the following-
a) the sequence and interaction of all spets in the operation
b) any outsouced processes and subontracted work
c) where raw materials, ingredients and intermediate products enter the flow
d) where reworking and recycling take place
e) where end produts, intermediate products, by products and waste are released or removed

Although you have tried to cover these aspects in the flowdiagrams, still few things are missing. eg. if you are adding water, sugar etc.

Once you have correctly designed the process flow diagarm, you shall be able to identify potential hazard that may enter during each step and finally how you are going to control these hazards.

Regards

Thank you very much Charles, Tripathiji & Saviour,

as i am new to this system it is possible to implement & documentation with the help of IFSQN by taking reference of various threads and by the guidance of senior menbers like you.

I am working on it and might finalise all requirements (few expertise inputs needed to OPRPs & HACCP) and might have preaudit in few days.
Thak you all again.
I will inform in the same thread after having sucessful audit.

Regards,
Sachin

Yes, I had undergone training on BRC but not in HACCP ; HACCP system is one of the Fundamental clause in BRC but is not so descriptive like ISO 22K; in the training very less time had given for this clause.

This is my first year of post harvest experience and previously i was working in preharvest i.e. Agri inputs & research in plant pathology (field trials). Basically i am Agri alied post graduate.

My company had taken consultancy in BRC for handling of fresh fruits before my joining and as i had taken training in BRC, my Sr. management desires to work (to have certified in ISO 22K- for fruit processing) me without help (expense) of any consultant.

Now i want to make my career in food safety & seeks support from Sr. members of IFSQN.

Regards,
Sachin

Dear Sachin Saindane,

HACCP system is one of the Fundamental clause in BRC but is not so descriptive like ISO 22K; in the training very less time had given for this clause.

I would suggest you take another course in HACCP. Urgently.

Rgds / Charles.C

Thank u very much Siraj,

I have found your prompt replies on many topics and feeling lucky to have the experienced friends like you in this forum.
The checklist given by you is the same i had prepared few days before my self and i had finished most of the tasks upto No. 7 as given by you. Also i had prepared some procedures against clause No. 4.2, 5.4,5.7,5.8,6.2.2,7.8, 7.10, 8.3, 8.4.1 & 8.5.

I am confused about Cause No. 8.2, 8.4.2 & 8.4.3 and seeks guidance about recording system of these.
In the attachement you can found 3 sheets of process flow in a single excel sheet and 3 another files of process description for each product.(Sorry for inconvenience as it will take significant time to go through this all)

Please guide me what are the correct OPRPs & HACCP plan. If u can give examples to be documented the same then it will be appreciable.

Thanks again for your efforts.

Regards,
Sachin Saindane

thank you so much